Dual-spectrum digital imaging welding helmet

ABSTRACT

Arc welding systems, methods, and apparatus that provide dual-spectrum, real-time viewable, enhanced user-discrimination between arc welding characteristics during an arc welding process. Welding headgear is configured to shield a user from harmful radiation and to include a digital camera or cameras to provide dual-spectrum (i.e., both visible spectrum and infrared spectrum) real-time digital video image frames. The welding headgear is also configured with an optical display assembly for displaying real-time digital video image frames to the user while wearing the headgear during an arc welding process. Image processing is performed on the visible and infrared spectrum video image frames to generate dual-spectrum video image frames providing an integrated and optimized view of both the visible and thermal characteristics of the arc welding process which can be viewed by the user on the optical display assembly in real time.

CROSS-REFERENCE TO RELATED APPLICATIONS AND INCORPORATION BY REFERENCE

This U.S. patent application is a continuation of and claims the benefitof U.S. non-provisional patent application Ser. No. 13/108,168 filed onMay 16, 2011, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

Certain embodiments relate to the visualization of arc weldingcharacteristics during an arc welding process. More particularly,certain embodiments relate to systems, methods, and apparatus (e.g., awelding helmet) providing dual-spectrum, real-time viewable, enhanceduser-discrimination between arc welding characteristics during an arcwelding process.

BACKGROUND

During an arc welding process, various forms of radiation are emittedincluding light in the visible, infrared, and ultraviolet spectrums. Theemitted radiation may be of high intensity and can harm the eyes and/orskin of the user if the user is not properly protected. Traditionally, auser wears a conventional welding helmet having a window with one ormore protective lenses to reduce the intensity of the radiation to safelevels. However, such protective lenses, while providing adequateprotection for the user, reduce the amount of light through the lens anddo not allow the user to see the visible characteristics of the arcwelding process in an optimal manner. For example, certain visiblecharacteristics of the arc and/or the molten metal puddle may befiltered out which the user would prefer to see, or smoke from the arcwelding process may obscure the arc and/or the molten metal puddleduring portions of the process. Furthermore, such protective lenses donot allow the user to see the thermal or infrared characteristics of thearc, the puddle, or the surrounding metal at all. Also, users thatrequire corrective lenses are disadvantaged when using conventionalhelmet and are restricted to using a few “cheater” lenses that providesome magnification.

Further limitations and disadvantages of conventional, traditional, andproposed approaches will become apparent to one of skill in the art,through comparison of such approaches with embodiments of the presentinvention as set forth in the remainder of the present application withreference to the drawings.

SUMMARY

Arc welding systems, methods, and apparatus that provide dual-spectrum,real-time viewable, enhanced user-discrimination between arc weldingcharacteristics during an arc welding process are disclosed herein. Awelding headgear is configured to shield a user from harmful radiationand to include a digital camera or cameras to provide dual-spectrum(i.e., both visible spectrum and infrared spectrum) real-time digitalvideo image frames. The welding headgear is also configured with anoptical display assembly for displaying real-time digital video imageframes to the user while wearing the headgear during an arc weldingprocess. Image processing is performed on the visible and infraredspectrum video image frames to generate dual-spectrum video image framesproviding an integrated and optimized view of both the visible andthermal characteristics of the arc welding process which can be viewedby the user on the optical display assembly. As a result, for a givenwelding process, a user is able to view desired visible and thermalcharacteristics of the arc welding process. Unwanted characteristics andobstructions are filtered out while wanted characteristics are preservedand enhanced, providing the user with maximum insight and awareness ofthe arc welding process in real-time. With such maximum insight andawareness, a user may more readily and effectively adapt his weldingtechnique to form a quality weld. For example, a user may be able tomore clearly view and understand the “freezing” or solidifyingcharacteristics of a weld puddle and have better instantaneous knowledgeof the weld, and thus be able to have more control resulting in a betterweld.

These and other features of the claimed invention, as well as details ofillustrated embodiments thereof, will be more fully understood from thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a first example embodiment of adual-spectrum digital imaging arc welding system for providing enhanceddiscrimination between arc welding characteristics;

FIG. 2 is an illustration of an exploded view of the system of FIG. 1showing various elements of the system;

FIG. 3 is a schematic block diagram of the embodiment of thedual-spectrum digital imaging arc welding system of FIG. 1 and FIG. 2showing various imaging elements;

FIG. 4 is a schematic block diagram of an example embodiment of a visionengine used in the system of FIGS. 1-3;

FIG. 5 is a flowchart of an embodiment of a method of generatingenhanced dual-spectrum real-time digital video of a welding processusing the system of FIGS. 1-4;

FIG. 6 is a schematic block diagram of a second example embodiment of adual-spectrum digital imaging arc welding system providing enhanceduser-discrimination between arc-welding characteristics; and

FIG. 7 is a schematic block diagram of a third example embodiment of adual-spectrum digital imaging arc welding system providing enhanceduser-discrimination between arc-welding characteristics.

DETAILED DESCRIPTION

Embodiments of the present invention are concerned with systems,methods, and apparatus providing dual-spectrum (e.g., visible-spectrumand infrared-spectrum), real-time viewable, enhanced visibility of arcwelding characteristics during an arc welding process. In accordancewith certain embodiments of the present invention, such capability isprovided in a dual-spectrum welding helmet worn by the user performingthe welding process.

As used herein, the term “physically integrated” refers to beingpositioned on, being an integral part of, or being attached to (with orwithout the capability to be subsequently unattached). As used herein,the term “real-time” refers to significantly maintaining the temporalcharacteristics of an imaged welding process scene with minimal orlargely imperceptible delay between image capture and display.

Details of various embodiments of the present invention are describedbelow herein with respect to FIGS. 1-7. FIG. 1 is an illustration of afirst example embodiment of a dual-spectrum digital imaging arc weldingsystem 100 for providing enhanced discrimination between arc weldingcharacteristics to a user. The system 100 of FIG. 1 includes a weldinghelmet (welding headgear) or welding shield 110 that is worn by a welderduring a welding process. The welding helmet 110 does not have a windowwith, for example, a glass filter lens as certain conventional weldinghelmets have. Instead, the system 100 includes a welding helmet 110 thathas digital imaging technology integrated into the helmet 110 to captureand display desired aspects of the welding process scene to the welder.Both visible-spectrum (VS) and infrared-spectrum (IRS) energy from thewelding process are sensed through a VS lens 120 and an IRS lens 130,respectively on the front of the helmet 110.

FIG. 2 is an illustration of an exploded view of the system 100 of FIG.1 showing various elements of the system 100, including various imagingelements that are physically integrated into the welding helmet 110. Thesystem 100 includes a removable lens cover 140 having the VS lens 120and the IRS lens 130. The lens cover 140 attaches to the helmet 110 atthe front of the helmet 110. When removed, the lens cover 140 reveals avisual-spectrum (VS) digital camera 150, an infrared-spectrum (IRS)digital camera 160, and a vision engine 170. When the lens cover 140 isattached to the helmet 110, the lenses 120 and 130 operatively integratewith their respective cameras 150 and 160 which are used tosimultaneously capture visible-spectrum light and infrared-spectrumlight from a welding process scene, and generate raw visible-spectrum(VS) real-time digital video image frames and raw infrared-spectrum(IRS) real-time digital video image frames. In accordance with anembodiment of the present invention, the cameras 150 and 160 arehigh-definition, high speed video cameras capable of generating imageframes in real-time. Furthermore, the cameras 150 and 160 may provideeither grayscale or color pixel information, in accordance with variousembodiments of the present invention.

The system 100 also includes a vision engine 170 that operativelyinterfaces with the cameras 150 and 160. The vision engine 170 receivesthe raw VS and IRS real-time digital video image frames from the cameras150 and 160 and performs image processing on the digital video imageframes to create dual-spectrum (DS) real-time digital video image frameswhich combine desired VS and IRS image attributes from the respective VSand IRS imaging frames. As described later herein in more detail, thevision engine 170 first generates pre-processed VS and IRS digital videoimage frames from the corresponding raw digital video image frames andthen proceeds to generate the DS real-time digital video image framesfrom the pre-processed VS and IRS frames. In accordance with anembodiment of the present invention, the welder may choose to view theDS, pre-processed VS, or pre-processed IRS real-time digital video imageframes during the welding process.

The system 100 further includes an optical display assembly comprisingan LCD display 180 and a set of optics 190. The LCD display 180operatively interfaces to the vision engine 170 to receive processedreal-time digital video (e.g., DS real-time digital video image frames)from the vision engine 170. In accordance with an embodiment of thepresent invention, the LCD display 180 is a full-color high-resolutiondisplay capable of being updated in real-time. The optics 190operatively interfaces to the LCD display 180 to project the processedreal-time digital video to the eyes of the welder within the helmet 110.In accordance with an embodiment of the present invention, the optics190 includes a configuration of high resolution reflective mirrors,optical lenses, and electronics that may be configured to focus thewelding process scene such that the welding process scene appears at acorrect distance from the welder. The optics 190 may provide othercapabilities as well including, for example, a zoom feature. Such afeature may selectable via a user interface (see schematic element 310of FIG. 3) operatively interfacing to the optical display assembly.

FIG. 3 is a schematic block diagram of the embodiment of thedual-spectrum digital imaging arc welding system 100 of FIG. 1 and FIG.2 showing various imaging elements. As illustrated in FIG. 3, the VSdigital camera 150 provides raw VS video image frames to the visionengine 170. Similarly, the IRS digital camera 160 provides raw IRS videoimage frames to the vision engine 170. The term “raw” is used herein tomean that the video image frames have only been optically andelectronically processed by the cameras 150 and 160 and not yet by thevision engine 170, and that the video image frames out of the cameras150 and 160 are highly representative of all aspects of the weldingprocess scene including both wanted and unwanted attributes of thescene. That is, the raw video image frames have not yet been processedby the vision engine 170 to enhance those attributes that the welderdesires to view, and to remove those attributes that the welder does notdesire to view (e.g., obstructions). However, the lenses 120 and 130and/or the cameras 150 and 160 may provide some optical filtering to,for example, cut down on glare from the arc.

The vision engine 170, upon receiving the raw VS and IRS digital videoimage frames from the cameras 150 and 160, proceeds to process the rawimage frames to produce dual-spectrum (DS) real-time digital video imageframes (i.e., image frames that combine both visible-spectruminformation and infrared-spectrum information from the original rawimage frames) which largely maintain the desirable real-timecharacteristics of the welding process scene. The DS real-time digitalvideo image frames are provided to the optical display assembly 180/190for viewing by the welder.

In accordance with an embodiment of the present invention, the visionengine is configured to also generate enhanced visible-spectrum (VS)real-time digital video image frames and enhanced infrared-spectrum(IRS) real-time digital video image frames. As a result, a welder (user)may be able to select, via the user interface 310, which of the threetypes of video (DS, enhanced VS, enhanced IRS) to display on the opticaldisplay assembly. Furthermore, in accordance with an embodiment of thepresent invention, the system 100 is configured to allow a user toselect an imaging mode from a plurality of selectable and pre-definedimaging modes via the user interface 310. In accordance with variousembodiments of the present invention, the user interface 310 may beintegrated into the welding helmet 110 (e.g., as push-buttons on theside of the helmet), or may be a physically separate apparatus thatinterfaces in a wired or wireless manner with the helmet.

An imaging mode corresponds to a pre-defined configuration of imageprocessing to be performed by the vision engine. For example, oneimaging mode may be defined to display infrared-spectrum informationassociated with the molten welding puddle and visible-spectruminformation associated with the arc. Similarly, another imaging mode maybe defined to display visible-spectrum information associated with themolten welding puddle and infrared-spectrum information associated withthe arc. Still, another imaging mode may be defined to display blendedvisible-spectrum and infrared-spectrum information associated with themolten metal puddle, infrared-spectrum information associated with themetal workpiece away from the molten metal puddle, and visible-spectruminformation associated with the electrode wire and the arc. Many otherimaging modes are possible as well.

In accordance with an embodiment of the present invention, the system100 is configured to allow a user to change an imaging parameter presetto one of a plurality of selectable and pre-defined imaging parameterpresets. An imaging parameter preset corresponds to a pre-definedsetting of an imaging parameter. For example, one imaging parameterpreset may be a color map. The system 100 may provide a plurality ofcolor maps that a user may select when viewing, for example,infrared-spectrum information. Another imaging parameter preset may be alevel of spatial filtering or smoothing. The system 100 may provide aplurality of levels of spatial filtering that a user may select whenviewing, for example dual-spectrum information. Still, another imagingparameter preset may be a level of temporal filtering or smoothing. Thesystem 100 may provide a plurality of levels of temporal filtering thata user may select in order to, for example, filter out obstructing smokefrom the displayed video.

FIG. 4 is a schematic block diagram of an example embodiment of a visionengine 170 used in the system 100 of FIGS. 1-3. The vision engine 170takes the raw VS video image frames, from the VS video camera 150, intoa first visible-spectrum (VS) image processor 171. The VS imageprocessor 171 operates on the raw VS video image frames to generateprocessed (or pre-processed) VS video image frames. The raw VS videoimage frames are processed by the VS image processor 171 to enhance theusable visible-spectrum information (e.g., certain visiblecharacteristics of the welding arc) in the video frames and to removeunwanted information (e.g., smoke). The various image processingfunctions that may be performed by the VS image processor 171 include,for example, spatial filtering, thresholding, temporal filtering,spectral filtering, contrast enhancement, edge enhancement, and colormapping. Other types of image processing functions are possible as well,in accordance with various embodiments of the present invention.

Similarly, the vision engine 170 takes the raw IRS video image frames,from the IRS video camera 160, into a second infrared-spectrum (IRS)image processor 173. The IRS image processor 173 operates on the raw IRSvideo image frames to generate processed (or pre-processed) IRS videoimage frames. The raw IRS video image frames are processed by the IRSimage processor 173 to enhance the usable infrared-spectrum informationin the video frames (e.g., certain thermal characteristics of the moltenmetal puddle) and to remove unwanted information (e.g., backgroundtemperature of a workpiece). Similarly, the various image processingfunctions that may be performed by the IRS image processor 173 include,for example, spatial filtering, thresholding, temporal filtering,spectral filtering, contrast enhancement, edge enhancement, and colormapping. Other types of image processing functions are possible as well,in accordance with various embodiments of the present invention. Theimage processors may include buffers and memory for passing image framesin and out, and for temporarily storing processed image frames atvarious intermediate steps, for example.

The resultant enhanced VS and IRS real-time digital video image framesmay be output to the optical display assembly 180/190 for display to theuser (e.g., upon user selection of one or the other) and/or provided toa third dual-spectrum (DS) image processor 174 to generate combineddual-spectrum (DS) real-time digital image video frames. In accordancewith an embodiment of the present invention, the video frames cominginto the vision engine 170 from the cameras 150 and 160 are assumed tobe temporally aligned or correlated. That is, both cameras 150 and 160operate at a same acquisition frame rate and, therefore, any image framecoming into the VS image processor 171 at a particular time is assumedto correspond in time to an image frame coming into the IRS imageprocessor 173 at that same particular time. However, in accordance withcertain other embodiments, the VS image processor 171 and/or the IRSimage processor 173 may be “tuned”, “tweaked”, or calibrated totemporally align the video frames of one to the other. Alternatively, aseparate video frame temporal aligning apparatus may be provided in thevision engine to temporally align the VS and IRS image frames.

Furthermore, as can be seen from FIG. 1, the lenses 120 and 130 arespatially offset from each other on the lens cover 140. This may resultin a certain amount of spatial misalignment between the pixels of a VSimage frame and the pixels of an IRS image frame that are otherwisetemporally correlated or aligned. In accordance with an embodiment ofthe present invention, the lenses 120 and 130 are positioned andcalibrated to make sure that raw VS image frames are spatially alignedwith the raw IRS video image frames. Such calibration techniques arewell known in the art.

However, as an option, the temporally aligned VS and IRS video framesout of the respective image processors 171 and 173 may be spatiallyaligned by an optional video frame aligning apparatus 172. The videoframe aligning apparatus 172 uses a spatial aligning algorithm tospatially line up or match the pixels of a VS frame to an IRS framebefore providing the frames to the DS image processor 174. Such aspatial aligning algorithm may be anything from a sophisticatedalgorithm that implements state-of-the-art aligning techniques to asimple offset routine that simply applies a known, calibrated offset tothe image frames in one or more spatial directions. Such aligningtechniques are well-known in the art.

Once the enhanced (i.e., processed) VS and IRS video frames are providedto the DS image processor 174, the DS image processor 174 proceeds toprocess temporally correlated pairs of VS and IRS image frames toproduce DS image frames, containing both visual-spectrum and infraredspectrum information in each video frame. The DS image processor 174performs image processing on the pairs of image frames on apixel-by-pixel basis to decide if a given DS pixel derived from a givenpair of image frames should contain VS information, IRS information, orsome blended combination of the two.

Various image processing decision making algorithms may be applied tomake the VS/IRS pixel decision. For example, one image processingalgorithm may be configured to assign IRS information to those pixelshaving IRS data falling within a defined thermal range, and assigning VSinformation to all other pixels falling outside of that thermal range.This may be the case when it is known that the thermal characteristicsof the molten metal puddle of the selected welding process are verydifferent from the thermal characteristics of the arc. As a result, thethermal characteristics of the puddle can be discriminated from thethermal characteristics of the arc. The thermal characteristics of thepuddle may be displayed to the user while displaying enhanced visualcharacteristics of the arc, or vice-versa.

Furthermore, just as for the image processors 171 and 173, the variousimage processing functions that may be performed by the DS imageprocessor 174 may include, for example, spatial filtering, thresholding,temporal filtering, spectral filtering, contrast enhancement, edgeenhancement, and color mapping. Other types of image processingfunctions are possible as well, in accordance with various embodimentsof the present invention.

Even if the raw image data from the cameras is in the form of grayscaledata, the resultant DS images (and enhanced VS and IRS images) can becolor coded by applying color maps to the pixel data. The various imageprocessors 171, 173, and 174 may be, for example, digital signalprocessors (DSPs) or programmable processors running image processingsoftware, in accordance with various embodiments of the presentinvention. Other types of processors may be possible as well, inaccordance with other embodiments of the present invention. The imageprocessing is done in real time so as to largely maintain the real-timeor temporal characteristics of the imaged welding process scene.

FIG. 5 is a flowchart of an embodiment of a method 500 of generatingenhanced dual-spectrum real-time digital video of a welding processusing the system 100 of FIGS. 1-4. In step 510 of the method 500, raw VSand raw IRS real time digital video image frames of a welding processare captured via a shielding apparatus worn by a welder performing thewelding process to shield the welder from harmful radiation (e.g.,bright visible light, heat, ultraviolet light) emitted by the weldingprocess. In step 520, the raw VS real-time digital video image framesare pre-processed to generate pre-processed VS real-time digital videoimage frames by maintaining and enhancing desired visual-spectrumattributes of the welding process and by removing unwantedvisual-spectrum attributes of the welding process.

In step 530, the raw IRS real-time digital video image frames arepre-processed to generate pre-processed IRS real-time digital videoimage frames by maintaining and enhancing desired infrared-spectrumattributes of the welding process and by removing unwantedinfrared-spectrum attributes of the welding process. In step 540 (anoptional step), temporally correlated pairs of VS and IRS pre-processedimage frames are spatially aligned. In step 550, the temporallycorrelated pairs of image frames of the pre-processed VS and IRS imageframes are further processed to generate dual-spectrum (DS) real-timedigital video image frames. In step 560, one of the DS real-time digitalvideo image frames, the pre-processed VS real-time digital video imageframes, and the pre-processed IRS real-time digital video image framesis displayed to the welder via the shielding apparatus (e.g., via theoptical display assembly 180/190 integrated into the helmet 110) as thewelder wars the shielding apparatus during the welding process. Again,the user may select which video channel (VS, IRS, or DS) is to bedisplayed. Again, each pixel of each frame of the DS real-time digitalvideo image frames corresponds to visual-spectrum information,infrared-spectrum information, or a blending of visual-spectruminformation and infrared-spectrum information.

In accordance with an embodiment of the present invention, particularimage processing functions performed as part of the pre-processing ofthe raw VS real-time digital video image frames are selectable from aplurality of image processing options. Similarly, particular imageprocessing functions performed as part of the pre-processing of the rawIRS real-time digital video image frames are selectable from a pluralityof image processing options. Furthermore, particular image processingfunctions performed as part of the processing to generate the DSreal-time digital video image frames are selectable from a plurality ofimage processing options. Also, in accordance with an embodiment of thepresent invention, particular image processing functions performed aspart of the pre-processing steps and the processing step of the method500 are dependent on selection of a welding process from a plurality ofwelding processes.

FIG. 6 is a schematic block diagram of a second example embodiment of adual-spectrum digital imaging arc welding system 600 providing enhanceduser-discrimination between arc-welding characteristics for a user. Thesystem 600 includes a welding helmet 610 having the lenses, cameras, andthe optical display assembly of FIG. 2 physically integrated therewith.However, the system 600 also includes a welding power source and/or awelding wire feeder 620. In the embodiment of FIG. 6, the vision engine170 is no longer physically integrated with the welding helmet but is,instead, integrated into the welding power source or the welding wirefeeder. In such an embodiment, raw digital video (both VS and IRS) issent from the cameras of the welding helmet to the vision engine 170 viawired or wireless means. Processed video (DS, VS, and IRS) is sent fromthe vision engine 170 back to the welding helmet via wired or wirelessmeans. The configuration of FIG. 6 may be desirable if, for example, thevision engine 170 would take up too much space within the helmet, or ifthe vision engine would cause the helmet to weigh too much if integratedinto the helmet. Alternatively, the vision engine could be mounted onthe outside of the helmet such as, for example, on the top of the helmetto save space interiorly. The vision engine 170 may receive informationfrom the welding power source and/or welding wire feeder 710 such as,for example, current selected welding mode, current electrode type, orcurrent selected welding waveform and/or polarity. Such information maybe used by the vision engine 170 to make image processing selections ordecisions. Furthermore, a user interface may be integrated into thewelding power source or the welding wire feeder to allow a user toselect imaging modes, imaging parameter presets, etc.

FIG. 7 is a schematic block diagram of a third example embodiment of adual-spectrum digital imaging arc welding system 700 providing enhanceduser-discrimination between arc-welding characteristics for a user. Thesystem 700 includes a welding helmet 610 having the lenses, cameras, andthe optical display assembly of FIG. 2 physically integrated therewith.However, the vision engine 170 is physically separate from the helmet.In such an embodiment, raw digital video (both VS and IRS) is sent fromthe cameras of the welding helmet to the vision engine 170 via wired orwireless means. Processed video (DS, VS, and IRS) is sent from thevision engine 170 back to the welding helmet via wired or wirelessmeans. The configuration of FIG. 7 may be desirable if, for example, thevision engine 170 would take up too much space within the helmet, or ifthe vision engine would cause the helmet to weight too much ifintegrated into the helmet. Again, alternatively, the vision enginecould be mounted on the outside of the helmet such as, for example, onthe top of the helmet to save space interiorly. As an option, the visionengine 170 may interface to a welding power source and/or welding wirefeeder 710 (e.g., wired or wirelessly) to, again, receive informationfrom the welding power source and/or welding wire feeder 710 such as,for example, current selected welding mode, current electrode type, orcurrent welding waveform and/or polarity. Such information may be usedby the vision engine 170 to make image processing selections ordecisions. Furthermore, a user interface may be integrated into thevision engine to allow a user to select imaging modes, imaging parameterpresets, etc.

In accordance with an enhanced embodiment of the present invention,non-imaging information may be generated, gathered, and displayed on thedisplay 180. For example, various guide information or help attributesmay be overlaid onto the displayed real-time video to aid the userduring the welding process. Such non-imaging information may include,for example, gun/torch angle or stick electrode angle, stick outdistance from the workpiece, travel speed of the gun/torch or stickelectrode, and gun/torch height or stick electrode height. Thenon-imaging information may be obtained from another system such as, forexample, a virtual reality welding simulation system which is tetheredinto the system 100 and is configured to spatially track at least thegun/torch or stick electrode. Alternatively, the non-imaging informationmay be generated by the system 100 itself by using at least one cameraof the system 100 to spatially track the welding gun/torch or stickelectrode, for example. In such an embodiment, the system 100 includes atracking module to perform the spatial tracking functions.

In accordance with an alternative embodiment of the present invention,the system includes one or more three-dimensional (3D) view cameras,allowing a user to see the arc welding process scene in a 3D manner. Theoptical display assembly is configured to allow 3D viewing of thewelding process scene by the user.

In accordance with an enhanced embodiment of the present invention,non-imaging information may be generated, gathered, and displayed on thedisplay 180. For example, various guide information or help attributesmay be overlaid onto the displayed real-time video to aid the userduring the welding process. Such non-imaging information may include,for example, gun/torch angle or stick electrode angle, stick outdistance from the workpiece, travel speed of the gun/torch or stickelectrode, and gun/torch height or stick electrode height. Thenon-imaging information may be obtained from another system such as, forexample, a virtual reality welding simulation system which is tetheredinto the system 100 and is configured to spatially track at least thegun/torch or stick electrode. Alternatively, the non-imaging informationmay be generated by the system 100 itself by using at least one cameraof the system 100 to spatially track the welding gun/torch or stickelectrode, for example. In such an embodiment, the system 100 includes atracking module to perform the spatial tracking functions.

Other non-imaging information may include recommendations (e.g., “speedup”, “slow down”, “adjust angle”, etc.). In fact, in accordance with anembodiment of the present invention, information obtained from thedual-spectrum video may be used to determine the recommendations. Forexample, if the thermal characteristics of the weld puddle indicate thatthe temperature of the weld puddle is too low, the system may display arecommendation to the user to slow down the travel speed of the torch toallow more thermal energy into the weld puddle. Other recommendationsare possible as well, based on well-known good welding technique and therelationships between resultant weld characteristics and weldingtechnique.

In summary, an embodiment of the present invention comprises adual-spectrum digital imaging arc welding system providing enhanceddiscrimination between arc welding characteristics. The system includesa welding headgear configured to be worn on a head of a user to shieldat least the eyes of the user from spectral radiation emitted by an arcwelding process. A visible-spectrum (VS) digital camera is physicallyintegrated with the welding headgear and configured to provide raw VSreal-time digital video image frames representative of the arc weldingprocess within a field-of-view of the VS digital camera. Aninfrared-spectrum (IRS) digital camera is physically integrated with thewelding headgear and configured to provide raw IRS real-time digitalvideo image frames representative of the arc welding process within afield-of-view of the IRS digital camera. An optical display assembly isphysically integrated with the welding headgear to present real-timedigital video images to the user while the user is wearing the weldingheadgear. A vision engine operatively interfaces with the VS digitalcamera, the IRS digital camera, and the optical display assembly. Thevision engine is configured to produce at least dual-spectrum (DS)real-time digital video image frames from the raw VS and raw IRSreal-time digital video image frames and display the DS real-time videoimage frames to the user via the optical display assembly.

The vision engine may be physically integrated with the welding headgearor may be physically separate from the welding headgear. For example,the system may include a welding power source, wherein the vision engineis physically integrated into and/or operatively interfaces with thewelding power source. The system may include a welding wire feeder,wherein the vision engine, instead, is physically integrated into and/oroperatively interfaces with the welding wire feeder.

The system may also include a user interface operatively interfacing toat least one of the vision engine and the optical display assembly. Theuser interface may be configured to allow a user to manually select animaging mode from a plurality of selectable and pre-defined imagingmode, or may be configured to allow a user to manually change an imagingparameter preset to one of a plurality of selectable and pre-definedimaging parameter presets.

In accordance with an embodiment of the present invention, the visionengine includes a first image processor configured to perform imageprocessing on the raw VS real-time digital video image frames togenerate processed VS real-time digital video image framesrepresentative of enhanced VS attributes of the welding process. Thevision engine also includes a second image processor configured toperform image processing on the raw IRS real-time digital video imageframes to generate processed IRS real-time digital video image framesrepresentative of enhanced IRS attributes of the welding process. Thevision engine further includes a third image processor configured toperform image processing on the processed VS real-time digital videoimage frames and the processed IRS real-time digital video image framesto generate the dual-spectrum (DS) real-time digital video image framesrepresentative of combined VS and IRS attributes of the welding process.The vision system may also include a video frame aligning apparatusconfigured to spatially align temporally correlated pairs of digitalvideo image frames of the processed VS real-time digital video imageframes and the processed IRS real-time digital video image frames beforeproviding the processed real-time digital video image frames to thethird image processor.

Another embodiment of the present invention comprises a dual-spectrumdigital imaging arc welding system providing enhanced discriminationbetween arc welding characteristics. The system includes means forshielding at least the eyes of a user from spectral radiation emitted byan arc welding process. The system further includes means for generatingraw visual-spectrum (VS) real-time digital video image framesrepresentative of visual-spectrum emissions of the arc welding process,wherein the means for generating raw visual-spectrum (VS) real-timedigital video image frames is physically integrated with the means forshielding, and means for generating raw infrared-spectrum (IRS)real-time digital video image frames representative of infrared-spectrumemissions of the arc welding process, wherein the means for generatingraw infrared-spectrum (IRS) real-time digital video image frames isphysically integrated with the means for shielding. The system furtherincludes means for displaying real-time digital video image frames,wherein the means for displaying is physically integrated with the meansfor shielding. The system also includes means for producing at leastdual-spectrum (DS) real-time digital video image frames from the raw VSand raw IRS real-time digital video image frames and providing at leastthe DS real-time digital video image frames to the means for displaying.

The means for producing at least dual-spectrum (DS) real-time digitalvideo image frames may be physically integrated with the means forshielding, or may be physically separate from the means for shielding.For example, the system may also include a welding power source whereinthe means for producing at least dual-spectrum (DS) real-time digitalvideo image frames is physically integrated into and/or operativelyinterfaces with the welding power source. The system may further includea welding wire feeder wherein the means for producing at leastdual-spectrum (DS) real-time digital video image frames, instead, isphysically integrated into and/or operatively interfaces with thewelding wire feeder.

The system may further include means for allowing a user to manuallyselect an imaging mode from a plurality of selectable and pre-definedimaging modes and/or means for allowing a user to manually change animaging parameter preset to one of a plurality of selectable andpre-defined imaging parameter presets.

The means for producing at least dual-spectrum (DS) real-time digitalvideo image frames may include means for performing image processing onthe raw VS real-time digital video image frames to generate processed VSreal-time digital video image frames representative of enhanced VSattributes of the welding process. The means for producing may alsoinclude means for performing image processing on the raw IRS real-timedigital video image frames to generate processed IRS real-time digitalvideo image frames representative of enhanced IRS attributes of thewelding process. The means for producing may further include means forperforming image processing on the processed VS real-time digital videoimage frames and the processed IRS real-time digital video image framesto generate DS real-time digital video image frames representative ofcombined VS and IRS attributes of the welding process. The means forproducing at least dual-spectrum (DS) real-time digital video imageframes may further include means for spatially aligning temporallycorrelated pairs of digital video image frames of the processed VSreal-time digital video image frames and the processed IRS real-timedigital video image frames before providing the processed VS and IRSreal-time digital video image frames to the means for performing imageprocessing on the processed VS and IRS real-time digital video imageframes.

A further embodiment of the present invention comprises a vision engine.The vision engine includes several image processors. A first imageprocessor is configured to perform image processing on raw VS real-timedigital video image frames to generate processed VS real-time digitalvideo image frames representative of enhanced VS attributes of a weldingprocess. A second image processor is configured to perform imageprocessing on raw IRS real-time digital video image frames to generateprocessed IRS real-time digital video image frames representative ofenhanced IRS attributes of the welding process. A third image processoris configured to perform image processing on temporally correlated pairsof the processed VS real-time digital video image frames and theprocessed IRS real-time digital video image frames to generate DSreal-time digital video image frames representative of combined VS andIRS attributes of the welding process. The vision engine may furtherinclude a video frame aligning apparatus configured to spatially alignthe temporally correlated pairs of digital video image frames of theprocessed VS real-time digital video image frames and the processed IRSreal-time digital video image frames before providing the processed VSand IRS real-time digital video image frames to the third imageprocessor.

Another embodiment of the present invention comprises a method ofgenerating enhanced dual-spectrum real-time digital video of a weldingprocess. The method includes capturing raw visual-spectrum (VS) and rawinfrared-spectrum (IRS) real-time digital video image frames of awelding process via a shielding apparatus worn by a welder performingthe welding process to shield the welder from harmful radiation emittedby the welding process. The raw VS real-time digital video image framesare pre-processed to generate pre-processed VS real-time digital videoimage frames by maintaining and enhancing desired visual-spectrumattributes of the welding process and by removing unwantedvisual-spectrum attributes of the welding process. The raw IRS real-timedigital video image frames are pre-processed to generate pre-processedIRS real-time digital video image frames by maintaining and enhancingdesired infrared-spectrum attributes of the welding process and byremoving unwanted infrared-spectrum attributes of the welding process.Temporally correlated pairs of image frames of the pre-processed VS andIRS real-time digital video image frames are then processed to generatedual-spectrum (DS) real-time digital video image frames. One of the DSreal-time digital video image frames, the pre-processed VS real-timedigital video image frames, and the pre-processed IRS real-time digitalvideo image frames is displayed to the welder via the shieldingapparatus as the welder wears the shielding apparatus during the weldingprocess in response to selection by the welder, for example.

In accordance with an embodiment of the present invention, each pixel ofeach frame of the DS real-time digital video image frames corresponds toone of visual-spectrum information, infrared-spectrum information, and ablending of visual-spectrum information and infrared-spectruminformation. The method may further include spatially aligning, on apixel-by-pixel basis, the temporally correlated pairs of image framesbefore processing the temporally correlated pairs of image frames togenerate the DS real-time digital video image frames.

Particular image processing functions performed as part of thepre-processing of the raw visual-spectrum (VS) real-time digital videoimage frames may be selectable from a plurality of image processingoptions. Similarly, particular image processing functions performed aspart of the pre-processing of the raw infrared-spectrum (IRS) real-timedigital video image frames may be selectable from a plurality of imageprocessing options. Also, particular image processing functionsperformed as part of the processing to generate the dual-spectrum (DS)real-time digital video image frames may be selectable from a pluralityof image processing options. Furthermore, particular image processingfunctions performed as part of the pre-processing steps and theprocessing step of the method may be dependent on selecting a weldingprocess form a plurality of welding processes.

Another embodiment of the present invention comprises a dual-spectrumdigital imaging arc welding system providing enhanced discriminationbetween arc welding characteristics to a user. The system includes awelding headgear configured to be worn on a head of a user and to shieldat least the eyes of the user from spectral radiation emitted by an arcwelding process. The system also includes a dual-spectrum (DS) digitalcamera physically integrated with the welding headgear and configured toprovide raw visible-spectrum (VS) real-time digital video image framesand raw infrared-spectrum (IRS) real-time digital video image frames.The system further includes an optical display assembly physicallyintegrated with the welding headgear and configured to present real-timedigital video images to the user while the user is wearing the weldingheadgear. The system also includes a vision engine operativelyinterfacing with the DS digital camera and the optical display assembly,wherein the vision engine is configured to produce at leastdual-spectrum (DS) real-time digital video image frames from the raw VSand raw IRS real-time digital video image frames.

While the claimed subject matter of the present application has beendescribed with reference to certain embodiments, it will be understoodby those skilled in the art that various changes may be made andequivalents may be substituted without departing from the scope of theclaimed subject matter. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the claimedsubject matter without departing from its scope. Therefore, it isintended that the claimed subject matter not be limited to theparticular embodiments disclosed, but that the claimed subject matterwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A system comprising: a welding headgearconfigured to be worn on a head of a user; at least one digital cameraconfigured to collect visible-spectrum digital video andinfrared-spectrum digital video; a vision engine operatively interfacingwith the at least one digital camera configured to combine thevisible-spectrum digital video and infrared-spectrum digital video toproduce a dual-spectrum digital video; and an optical display of thewelding headgear and configured to present the dual-spectrum digitalvideo to the user.
 2. The system of claim 1, wherein the vision enginecombines the visible-spectrum digital video and the infrared-spectrumdigital video by at least spatially aligning the visible-spectrumdigital video and the infrared-spectrum digital video.
 3. The system ofclaim 1, wherein the vision engine combines the visible-spectrum digitalvideo and the infrared-spectrum digital video by at least temporallyaligning the visible-spectrum digital video and the infrared-spectrumdigital video.
 4. The system of claim 1, wherein the at least onedigital camera is a dual-spectrum digital camera.
 5. The system of claim1, wherein the at least one digital camera includes a visible-spectrumdigital camera and an infrared-spectrum digital camera.
 6. The system ofclaim 1, wherein the at least one digital camera collects images in oneof grayscale or color.
 7. The system of claim 1, wherein the visionengine is further configured to process non-imaging information, andwherein the optical display of the welding headgear is furtherconfigured to present the non-imaging information to the user.
 8. Thesystem of claim 7, wherein the non-imaging information is overlaid ontothe dual-spectrum digital video.
 9. The system of claim 7, wherein thenon-imaging information includes at least one of gun/torch angle,electrode angle, stick out distance, distance from workpiece, travelspeed, gun/torch height, and electrode height.
 10. The system of claim7, wherein the non-imaging information includes recommendations for theuser.
 11. A method, comprising: capturing visible-spectrum video imageframes of a welding process using a shielding apparatus worn by a welderperforming the welding process; capturing infrared-spectrum video imageframes of the welding process using the shielding apparatus worn by thewelder performing the welding process; processing the visible-spectrumvideo image frames and the infrared-spectrum video image frames toproduce at least blended visible-spectrum and infrared-spectruminformation; and displaying at least the blended visible-spectrum andinfrared-spectrum information using the shielding apparatus worn by thewelder performing the welding process.
 12. The method of claim 11,further comprising spatially aligning the visible-spectrum video imageframes and infrared-spectrum video image frames during processing. 13.The method of claim 11, further comprising temporally aligning thevisible-spectrum video image frames and infrared-spectrum video imageframes during processing.
 14. The method of claim 11, furthercomprising: gathering non-imaging information related to the weldingprocess; and displaying the non-imaging information using the shieldingapparatus worn by the welder performing the welding process.
 15. Themethod of claim 14, wherein the non-imaging information is overlaid ontothe blended visible-spectrum and infrared-spectrum information.
 16. Themethod of claim 14, wherein the non-imaging information includes atleast one of gun/torch angle, electrode angle, stick out distance,distance from workpiece, travel speed, gun/torch height, and electrodeheight.
 17. A system, comprising: means for capturing visible-spectrumvideo image frames of a welding process using a shielding apparatus wornby a welder performing the welding process; means for capturinginfrared-spectrum video image frames of the welding process using theshielding apparatus worn by the welder performing the welding process;means for processing the visible-spectrum video image frames and theinfrared-spectrum video image frames to produce at least blendedvisible-spectrum and infrared-spectrum information; and means fordisplaying at least the blended visible-spectrum and infrared-spectruminformation using the shielding apparatus worn by the welder performingthe welding process.
 18. The system of claim 17, further comprising:means for gathering non-imaging information related to the weldingprocess; and means for displaying the non-imaging information using theshielding apparatus worn by the welder performing the welding process.19. The system of claim 18, wherein the non-imaging information isoverlaid onto the blended visible-spectrum and infrared-spectruminformation.
 20. The system of claim 18, wherein the non-imaginginformation includes at least one of gun/torch angle, electrode angle,stick out distance, distance from workpiece, travel speed, gun/torchheight, and electrode height.